Steam iron



Oct. 13, 1959 D. E. cLAPP 2,908,092

STEAM IRON Filed Oct. l0, 1955 3 Sheets-Sheet l Oct. 13, 1959 D. E. cLAPP 2,908,092

STEAM IRON Filed oct. 1o, 1955 K s sheets-sheet 2 "im: la:

I i Z4 248 24 A Oct. 13, 1959 D. E. CLAPP 2,908,092

STEAM IRON Filed oct. 1o, 1955 s sheets-sheet s United States Patent O STEAM IRON Daniel E. Clapp, Philadelphia, Pa., assignor, by mesne assignments, to Proctor Manufacturing Corporation, Rio Piedras, Puerto Rico, a corporation of Delaware Application October 10, 1955, Serial No. 539,515 8 Claims. (Cl. 38-77) This invention relates to steam irons and more particularly to steam irons of the ash boiler type.

The principal object of the invention is to provide an improved steam iron which is simple in construction, easy to assemble, and highly e'icient in operation.

Another object of the invention is to provide a steam iron having a steam generating chamber of large area and of novel construction and arrangement to effect ellicient operation and to minimize heat transfer to the water reservoir located above said chamber.

Still another object of the invention is to provide a steam iron which can be easily iilled with water and emptied with virtually no possibility of the water coming in 'contact with the electrical components of the iron.

A further object of the invention is to provide a front iilled steam iron in which water sloshing is minimized and water ejection is prevented.

A further `object of the invention is to provide a steam iron employing an easily controllable needle valve for controlling the supply of water from the water reservoir to the steam chamber.

In accordance with one feature of the invention, the steam generating chamber is comprised of a walled portion of the sole plate having communicating channels leading to the steam emission aperture or passages, and a lid or cover formed of sheet metal having low heat conductivity and adapted to be secured to the chamberdefining wall of the sole plate by means of a groove in said wall and a lip on said lid. Thus, there is provided a canister-type closure for the steam generating chamber, enabling easy assembly and insuring a tight seal, and also enabling easy cleaning of the said chamber in the event that this becomes necessary. The construction of the steam generating chamber and its relation to the heating element are such that the water from the reservoir is supplied to the steam chamber at a relatively cool portion of the sole plate, and the channels in said chamber extend over portions of the sole plate which are progressively higher in temperature.

Another feature of the present invention relates to the problem of steam or Vapor generation in the water reservoir and water ejection through the lill arrangement. In any steam iron of the flash boiler type, the generation of steam or vapor in the water reservoir is bound to occur. In prior steam irons of this type having a relatively short lill spout, a multitude of anti-slosh bailes have been provided in the water reservoir in an eiort to prevent `ejection of water through the short lill spout due to sloshing of the water during the to and fro movement of the iron. However, the multitude of bailes have tended to cause steam pockets and build-up of pressure, with consequent ejection of water.

The present invention overcomes this objection by providing a relatively long lill spout and a single anti-slosh baille. Although some generation of steam or vapor will occur, there is no formation of steam pockets and there is no ejection of water. In the preferred structure, the water reservoir s provided with an anti-slush balie near its front, and a filling spout is provided which extends upwardly from the front of the reservoir and forwardly at the top of the iron to the ll entrance. Thus the iron is front iilled at the top when it is up-ended. This lling arrangement and the anti-slosh baille serve cooperatively to prevent any ejection of water. The filling arrangement also enables easy lling and emptying of the iron, with virtually no possibility of water coming in contact with the electrical components.

Other objects and features of the invention will be apparent from the following detailed description with reference to the accompanying drawings, wherein Fig. 1 is a side elevational view of a steam iron embodying the invention, with portions broken away to show internal parts;

Fig. 2 is a view taken on line 2 2 of Fig. l, showing the upper portion of the handle in front elevation, and showing the lower part of the iron in transverse section;

Fig. 3 is a cross sectional View taken on line 3 3 of Fig. 1;

Fig. 4 is a fragmentary cross sectional view taken through the controlling valve and along the operating rod therefor;

Fig. 5 is a plan view of the sole plate and the steam generating chamber, with approximately one-half of the lid or cover of said chamber broken away for the purpose of illustration;

Fig. 6 is a bottom view of the sole plate;

Fig. 7 is a longitudinal sectional View of the sole plate and the steam generating chamber, taken along line 7 7 of Fig. 5;

Fig. S is a cross sectional View of the sole plate and the steam generating chamber, taken along line 8 8 of Fig. 5;

Fig. 9 is a perspective view of the water reservoir and its filling spout, with a portion of the reservoir broken away to show the anti-slosh baille;

Fig. 9ais a perspective view of the spring employed in association with the water reservoir;

Fig. l0 is a fragmentary perspective view of the front part of the water reservoir taken so as to show the bottom of said portion;

Fig. 1l is a perspective view of the sole plate;

Fig. 12 is a perspective view of the lid or cover of the steam generating chamber, with a portion broken away to show the construction more clearly; and

Fig. 13 is a fragmentary sectional view similar to a lower part of Fig. 2 and showing a modiication.

Referring iirst to Figs. l and 2, the illustrated steam iron comprises a sole plate 10 having embedded therein a heating element 11 of the rod type, a steam generating chamber 12, a water reservoir 13 above the steam generating chamber, an adjustable thermostatic control mechanism 14 extending upwardly from the sole plate, a cover or shell 15 serving to enclose the parts immediately above the sole plate, and a handle 16 having a front column 17 which is hollow to accommodate the upper part of the thermostatic control mechanism 14 and also to accommodate the filling spout 18 of the water reservoir and the control mechanism for valve 19 which controls the supply from the water reservoir 13 to the steam generating chamber v12.

The thermostatic control mechanism 14 and its generally vertical disposition at the front of the steam iron form the subject of a copending application of R. H. Houck, Serial No. 539,592, filed October 10, 1955, assigned to the assignee of the present application. The present invention is not concerned with the details of the thermostatic control mechanism, and for the present purpose it suces to note that this mechanism comprises a switch 20 adjustable by means of a knob 21 extending from the front of the handle and a thermomotive member 22 which actuates switch 20 in response to the temperature of the portion of the sole plate on which the -control mechanism is mounted. As may be seen in Fig. 5, the heating "element 11 :extends along the side portions of the sole plate and generally -conforms to the contour of the sole plate and the thermostatic switch 20 is connected in series with the heating element by means of connector rods 23 and 24 which* extend above the side portions of the sole plate and are supported by insulating supports 25 and 26. Connector rod 23 extends from one element of the thermostatic switch to one terminal 27 of the heating element. Connector rod 24 `extends from the other element of the thermostatic switch to a main terminal 28 of the iron. The other main terminal 29 is connected by a connector rod 30 to the other terminal 31 of the heating element.

It should be noted that the thermomotive member 22 engages the sole plate at a point between, and preferably substantially equi-distant from, the heating element and the point at which water drops onto the sole plate. Member 22 is therefore quickly responsive to temperature changes of the sole plate during both steam ironing and dry ironing.

'An important feature of the present invention is the construction and arrangement of the steam generating chamber as shown in Figs. 5, 7, 8, l1 and 12. YAs may be seen in Figs. and 11, the steam generating chamber is of large ovate form occupying most of the sole plate area within the contines of the heating element 11. This chamber is defined by a wall 32 forming an integral part of the sole plate and having an upwardly-facing groove 33. A sheet metal lid or cover 34, preferably formed of stainless steel and having low heat conductivity, is adapted Vfor application to the chamber-defining wall 32 by having a U-shaped lip 35 which tits into the groove 33. Being formed of .stainless steel, the lid has anticorrosive characteristics, and its low heat conductivity minimizes heat transfer to the water reservoirwhich is disposed above the steam generating chamber. vThisrninimizes boiling of water in the reservoir when the water supply valve is closed and the heating` element is energized. During assembly, the U-shaped lip 35 isV forced into the groove 33, and the act of assembly effects a broaching action on the walls of the groove 33 in the relatively soft aluminum sole plate by the relatively hard material of the lipl 35. The dimensions of the groove 33 and the lip 35 are selected so that there is a compression of the lid with consequent slight buckling of the' central portion thereof upon assembly. As the sole plate heats, the more rapidly expanding aluminum increases the size of the oval area, effectively removing the buckling of the lid andY causing some pretensioning of the lid. Thus, it will be seen that the steam generating chamber is novelly characterized in that it employs a canister-type closure which is easily applied and eifects a tight seal without the use of fastening or sealing elements, and which can be removed for cleaning of the chamber in the event that this becomes necessary.

The lid or cover 34 of the steam generating chamber has an opening 36 at the front end thereof, and as 'shown in Figs. 2 and 4, a downwardly extending flange 37 defines the opening and serves to seat the tapered body of valve 19. When the valve is open, water is supplied in successive drops to the front area 38 (see Fig. 11) of a central channel 39 formed in the steam chamber. As may be seen in Fig. 8, this central channel is relatively deep and has a relatively thin floor or bottom 40.Y On the opposite sides of the central channel 39, there are shallower channels 41 and 42 having relatively thicker floors or bottoms 43 and 44. As may be seen in Fig. ll, these latter channels communicate with the central channel at the relatively low bale sections 45 and 46. Two outer channels 47 and 48 communicate with channels 41 and 42 atvtheir front ends, as'may be seen in Fig. 11. These outer channels are even shallower than the adjacent channels and have the thickest lioors or bottoms 49 and 50.' Near the front ends of channels 41 and 42 are passage restrictions 51 and 52.

' in place.

With the constructionl just described, the water is supplied to the .steam generating chamber at a relatively cool portion of the sole plate which has a thin floor, and the two paths of travel from the central channel to the outermost channels extend over progressively thicker oor areas which are progressively hotter, the hottest portions being the thickest floor areas 49 and 50` which are in close proximity to the heating element. The thin floor of the central portion permits that portion to remain cool and prevents violent ebullition of the water entering the steam chamber. The paths of flow over portions of the sole plate of progressively increasing temperature cause complete conversion of water to steam and pred vent spitting. The ilow paths are long, and the flow is at relatively low velocity. From the two outermost channels 47 and 48, the steam is emitted through apertures-or passages arranged as shown in Figs. 6 to 8. These passages comprise vertical passages 53 and 54 extending downward from the channels 47 and 48, an oblique passage 55 extending in close proximity to the nose portion of the heating element and oblique passages 56 and 57, v

at the rear of the steam generating chamber. The arrangement of the passages effects good distribution of steam.

A further advantage of the steam chamber construction is that it provides ample space for build-up of minerals in the deep central channel where the water enters the chamber. Thus, a substantial accumulationvof mineral deposits from the water willnot block the ow passage. The bales serve to prevent entraiued water from passing to subsequent channels.

The water reservoir, as best shown in Figs. l', 9 and 10 comprises a body or shell 58 and a bottom 59 joined `to'gether by seaming at their peripheral edges. As may be seen in Fig. 4, the bottom 59 of the reservoir has a channel section 60 which is apertured to receive the valve body 19, the latter being swedged at 61 to hold it The valve body serves additionally to secure the horizontal portion 62 of an L-shaped baffle 63 (see Figs. 1 and 2) having apertures 64 therein. This baflie, which is disposed within the forward part of the water reservoir, limits sloshing of the water due to the to and fro motion -of the iron during ironing. This bafe and the relatively long generally vertical fill spout 18 with its forwardly facing entrance serve to prevent water from being forcibly ejected from the till spout.

The valve body 19, seated in the inlet opening of the steam generating chamber, serves to support and anchor the front portion of the water reservoir 13. The rear portion of the reservoir rests on pillars 65 which may be formed of heat-insulating material. The reservoir is pressed downwardly by a leaf spring 66 (see Figs. 1, 3 and 9a) which is retained by the handle and cover assembly. The downward pressure causes the valve body 19 to broach and seat itself into the lid of the steam chamber.

Asmay be seen in Fig. 4, the ller spout 18 and the operating mechanism for the valve are supported by a block 67 which is mounted on the top 58 ,of the water reservoir, the block having circular bosses 68 and 69 extending through circular apertures in the top of the reservoir and swedged over as shown. The lower end of the filling spout 18 seats within an opening 70 in the block 67 upon a shoulder 71. As shown in Fig. 1, the till spout extends upward within the hollow front column 17 of the handle, and its entrance is disposed at a front opening within which there is inserted a mouthpiece 72 forming part of a member 73 which also comprises a horizontal cover portion 74 overlying thel adjustment means for the thermostatic switch mechanism. The mouthpiece enters the entrance end of spout 18 and retains said end. At the rear of the iron, there are projections 75 and 76 to support the iron in an up-ended vertical position when it is not in use or when it is desired to till the iron. The fill spout location permits water to enter the iron with virtually no possibility of the water coming in contact with the thermostatic switch mechanism. With the iron in up-ended position, the entrance end of the ll spout faces upwardly, and it is an easy matter to pour water into the ll spout without permitting any water to spill into the slot which accommodates the manual element for adjusting the thermostatic switch mechanism. Further, when it is desired to remove any water remaining in the reservoir, as prior to storafge, the operator turns the iron from the up-ended position farther back to pour the water out of the ll spout.

Referring now to the control valve 19 and its operation, as shown in Fig. 4, this valve is a needle valve having a needle element 77 which is vertically movable to control the valve orilice. The needle element is carried at the lower end of a rod 78 whose upper portion extends through a bore 79 in block 67 and is slidably lguided by a fiber bushing 80 inserted in a recess 81 of the upwardly extending tubular portion 82. The upper end of rod 78 threadedly retains a nut 83 which is engaged by a helical spring 84 to urge the rod upwardly, i.e. `to urge the valve toward the open position. A second nut 85 serves to secure a finger element 86 to the upper end of rod 78. The upper end of iinger 86 engages a cam surface 87 within a guiding recess of a manual control element 88. The latter is formed as shown in Fig. 4, having a curved portion 89 by which it is slidably supported on a rod 90 anchored within the top of the front portion of the handle. A finger piece 91 extends through a slot 92 to enable manual movement of member 88. When the latter member is in the position shown in Fig. 1, it holds the valve closed, and when it is moved rearwardly, the rise of the cam surface 87 permits spring 84 to open the valve. Of course, the rise of the cam could be reversed to reverse the directions of operation.

From the foregoing description, it will be seen that the present invention provides a novel steam iron having features which contribute the advantages hereinbefore mentioned. It will be understood, of course, that the structural details may be modified without essential change of the iron. Fig. 13 shows a modification in which the valve operating rod 78a is straight instead of bent, and the valve 19a is olset from the central longitudinal axis and feeds into the steam generating chamber through a chute 93.

While a preferred embodiment of the invention has been illustrated and described, it will be apparent that other embodiments are possible while still retaining the important features and their advantages.

I claim:

1. In a steam iron, a sole plate having a covered steam generating chamber with a plurality of steam emission apertures through the bottom of the sole plate, valve means for introducing water into said steam generating chamber at a forward point in said chamber in the forward portion of said sole plate, an electric resistance heater element peripherally extending within the side and front portions of the sole plate enclosing the steam generating chamber on at least three sides, a portion being forward of the steam generating chamber, and thermostatic switch means including a thermomotive member forwardly of the chamber and attached to the sole plate in close thermal proximity to the ironing surface of said sole plate, the forward portion of said heating element and said point of water inlet.

2. In a steam iron, a sole plate, a generally U-shaped heating element peripherally extending within the side and front portions of the sole plate, a thermostat attached to the forward portion of the sole plate adjacent the part of the heating element in the front portion of the sole plate and adapted to occupy a small area, a steam generating and conveying chamber formed in the upper surface of said sole plate and lying in its entirety to the rear of said thermostat and occupying a major portion of the area of the sole plate made available for it by the location and larrangement of the thermostat, relatively narrow partitions dividing the chamber into tortuous paths including a deep central channel and relatively shallow outer channels in communication with said central channel at ends remote from water introduction, said sole plate having steam emission apertures communicating -with said outer ychannels and spaced longitudinally from each other along opposite sides of said steam generating chamber for a major portion of the length of the sole plate.

3. A steam iron according to claim 2 in which the steam emission apertures lie wholly within the confines of the heating element.

4. A steam iron according to claim 2, wherein said longitudinally extending chamber comprises two channels on each side of said central channel, there being a longitudinally extending intermediate channel between the central channel and each outer channel of intermediate depth Kand bottom thickness, the central channel communicating with each intermediate channel at the rear, and each intermediate channel communicating with the associated outer channel at the front.

5. A steam iron as defined in claim 4 in which said passages have substantially at bottoms.

6. In a steam iron, a sole plate, a heating element extending Within the side and front portions. of the sole plate, a thermostat attached to the forward portion of the sole plate and adapted to occupy ya Small area, a steam generating and conveying chamber occupying a major portion of the area of the sole plate made avail- `able by the location and arrangement of the thermostat, a water reservoir above said chamber, valve means interconnecting said chamber and saidreseivoir for introducing water into said chamber at a forward point of said chamber in the forward portion of the sole plate, a handle for the iron having a hollow front column with a front opening at its upper end, said column being adapted to house the following elements: valve control means for said valve means, manual adjustable means forsaid thermostat, and a fill spout connected at its lower end to said water reservoir and having an entrance at said upper front opening.

7. In a steam iron having formed therein a steam generating and conveying area, a sole plate comprising partitions defining a steam generating chamber having interconnected channels and having steam emission apertures communicating with said area, a groove in the upper surface of the sole plate around the peripheral walls of the steam generating chamber, a resilient sheet metal closure having a peripheral downwardly extending reversely bent lip, resiliently secured in the groove and lwith intermediate portions adapted to contact the upper surfaces of other partitions that define said interconnected channels whereby the channels are closed from one another except in the region of their interconnection, a water reservoir above said area, and means for controllably supplying water from said reservoir to said area.

8. A steam iron in accordance with claim 7 wherein said sheet metal closure is of stainless steel.

References Cited in the le of this patent UNITED STATES PATENTS 2,353,604 Waring et al. July 11, 1944 2,418,502 Ferguson Apr. 8, 1947 2,596,684 Hedenkamp May 13, 1952 2,608,773 Finlayson Sept. 2, 1952 2,637,126 Fitzsimmons May 5, 1953 2,655,746 McFarland et al. Oct. 20, 1953 2,668,378 Vance Feb. 9, 1954 2,683,320 Morton July 13, 1954 2,716,297 Hoecker Aug. 30, 1955 2,724,197 Beach Nov. 22, 1955 2,726,466 Sparklin Dec. 13, 1955 2,786,288 Beach Mar. 26, 1957 

